Local melting mechanism and its effects on mechanical properties of friction spot welded joint for Al-Zn-Mg-Cu alloy

Local melting and the eutectic film and liquation crack formation mechanisms during friction spot weld- ing （FSpW） of Al-Zn-Mg-Cu alloy were studied by both experiment and finite element simulation. Their effects on mechanical properties of the joint were examined. When the welding heat input was high, the peak temperature in the stir zone was higher than the incipient melting temperature of the Al-Zn-Mg-Cu alloy. This resulted in local melting along the grain boundaries in this zone. In the retreating stage of the welding process, the formed liquid phase was driven by the flowing plastic material and redistributed as a ＂U-shaped＂ line in the stir zone. In the following cooling stage, this liquid phase transformed into eutectic films and liquation cracks. As a result, a new characteristic of＂U＂ line that consisted of eutectic films and liquation cracks is formed in the FSpWjoin. This ＂U＂ line was located in the high stress region when the FSpW joint was loaded, thus it was adverse to the mechanical properties of the FSpW joint. During tensile shear tests, the ＂U＂ line became a preferred crack propagation path, resulting in the occurrence of brittle fracture.

Interface Characteristics and Evolution Mechanism of W/CuCrZr in Hot Melt Explosion Welding

Explosion welding was carried out on the basis of vacuum hot melt W/CuCrZr composite plate.Metallurgical microscope,scanning electron microscope and energy dispersive X-ray spectroscope were used to observe the microscopic morphology of the bonding interface.At the same time,combined with finite element calculations,the evolution mechanism of the interface of the hot melt explosion welded W/CuCrZr composite plate was explored.The results show that the interface bonding of the hot melt explosion welded W/CuCrZr composite plate is good and there is a cross-melting zone with 3–8μm in thickness,but cracks are developed on the W side.The numerical simulation reproduces the changes of pressure,stress,strain and internal energy at the bonding interface in the process of hot melt explosion welding.The location of the crack generated in the experiment coincides with the high stress position calculated by numerical simulation.The high pressure and high temperature near the hot melt explosion welding interface further promote the bonding of the interface.

Arc Behavior and Droplet Transfer of CWW CO_2 Welding

Cable-type welding wire（CWW）CO2 welding is an innovative process arc welding with high quality,high efficiency and energy saving,in which CWW is used as consumable electrode.The CWW is composed of seven wires with a diameter of 1.2mm.One is in the center,while others uniformly distribute around it.The diameter of twisted wire is up to 3.6mm,which can increase the deposition rate significantly.With continual wire-feeding and melting of CWW,the formed rotating arc improved welding quality obviously.The arc behavior and droplet transfer were observed by the electrical signal waveforms and corresponding synchronous images,based on the high speed digital camera and electrical signal system.The results showed that the shape of welding arc changed from bell arc to beam arc with the increase of welding parameter.The droplet transfer mode changed from repelled transfer,globular transfer to projected transfer in turn.Droplet transfer frequency increased from 18.17 Hz to 119.05 Hz,while the droplet diameter decreased from 1.5times to 0.3times of the CWW diameter.